Spray dried cacao pulp

ABSTRACT

The present disclosure is directed to a novel food ingredient, namely spray dried cacao pulp and spray dried cacao pulp on a carrier and methods of preparing and using the same.

BACKGROUND

Processing cacao beans to make chocolate yields numerous byproducts, including cacao pulp. During standard production, a majority of the pulp will go to waste. In order to increase efficiency and mitigate waste, researchers have sought ways to use cacao pulp in alternative preparations, including as a food ingredient.

As the food and confectionery industries respond to increased awareness of health and wellness concerns, finding ways to integrate fruits into novel raw ingredients increases importance. Using cacao pulp as an ingredient meets these desires and mitigates production waste.

Cacao pulp is sweet, with rich fruity flavors. Its flavor and sweetness render it desirable as raw ingredient to add flavor or sweetness or both to a food or confectionery product. However, as a raw pulp, it is a moisture rich product that is difficult to work with to incorporate into food or confectionery. While cacao pulp has been used in high moisture formulations, as described in, for example, WO2017062603, the disclosure of which is incorporated fully herein by reference, there have been technological barriers to its use in other types of food products, and particularly in food products or confectionery requiring low moisture. Thus, there is a need for new raw ingredients developed from cacao pulp for use in food or confectionery products.

BRIEF DESCRIPTION

The present disclosure is directed to spray dried cacao pulp as a food or confectionery ingredient and methods of preparing the same. The spray dried cacao pulp may be combined with a secondary raw material to derive a new raw material with beneficial functional properties as a food or confectionery ingredient and methods of preparing the same.

In light of the disclosure herein and without limiting the disclosure in any way, in a first aspect of the present disclosure, which may be combined with any other aspect listed herein unless specified otherwise, unprocessed cacao pulp is spray dried for use as food or confectionery ingredient. Minimally processed cacao pulp, such as pasteurized or commercially sterilized pulp, may be spray dried according to the presently claimed methods for use in the presently claimed products.

In a second aspect of the present disclosure, which may be combined with any other aspect listed herein unless specified otherwise, a confectionary composition includes spray dried cacao pulp prepared with a carrier selected from the group consisting of cocoa powder, cocoa butter, milk powder, or combinations thereof.

In a third aspect of the present disclosure, which may be combined with any other aspect listed herein unless specified otherwise, the milk powder is selected from the group consisting of non-fat dried milk powder, skim milk powder, whole milk powder, or powder prepared from milk substitutes or combinations thereof.

In a fourth aspect of the present disclosure, which may be combined with any other aspect listed herein unless specified otherwise, the composition does not comprise any added sugar.

In a fifth aspect of the present disclosure, which may be combined with any other aspect listed herein unless specified otherwise, a method is provided comprising manufacturing a food or confectionery ingredient comprising the steps of spray drying cacao pulp with a carrier.

In a sixth aspect of the present disclosure, which may be combined with any other aspect listed herein unless specified otherwise, the carrier with which the cacao pulp is spray dried is cocoa powder, cocoa pod fiber, cocoa butter or another product derived from a cocoa pod.

In a seventh aspect of the present disclosure, which may be combined with any other aspect listed herein unless specified otherwise, the cacao pulp is unprocessed prior to spray drying.

In an eighth aspect of the present disclosure, which may be combined with any other aspect listed herein unless specified otherwise, the spray drying occurs at an inlet temperature of 120° C. to 180° C.

In a ninth aspect of the present disclosure, which may be combined with any other aspect listed herein unless specified otherwise, the spray drying occurs at an outlet temperature of 60° C. to 100° C.

In a tenth aspect of the present disclosure, which may be combined with any other aspect listed herein unless specified otherwise, the spray drying occurs in a spray dryer coated with polytetrafluroethylene.

In an eleventh aspect of the present disclosure, which may be combined with any other aspect listed herein unless specified otherwise, a chewing gum is produced comprising spray dried cacao pulp. The chewing gum may comprise about 70% spray dried cacao pulp and about 30% gum base. The chewing gum may have no added sugar.

In a twelfth aspect of the present disclosure, which may be combined with any other aspect listed herein unless specified otherwise, a non-fat based confectionery product is produced comprising spray dried cacao pulp. The confectionery product may be a gummy candy.

In a thirteenth aspect of the present disclosure, which may be combined with any other aspect listed herein unless specified otherwise, the confectionery product comprising spray dried cacao pulp is a gelatin based confectionery product without added sugar.

In a fourteenth aspect of the present disclosure, which may be combined with the thirteenth aspect in combination with any other aspect listed herein unless specified otherwise, a method of minimizing the use of gelatin and starches in a confectionery product is provided, the method comprising replacing starch, gelatin, another texturizing agent or combinations thereof with spray dried cacao pulp.

In a fifteenth aspect of the present disclosure, which may be combined with any other aspect listed herein unless specified otherwise, a method of producing a chocolate or a compound coating is provided, the method comprising adding spray dried cacao pulp to the chocolate or the compound coating.

In a sixteenth aspect of the present disclosure, which may be combined with any other aspect listed herein unless specified otherwise, the spray dried cacao pulp is milled or conched separately from other ingredients prior to addition to the chocolate or the compound coating.

In a seventeenth aspect of the present disclosure, which may be combined with any other aspect listed herein unless specified otherwise, the milling or conching occurs at less than about 50° C.

In an eighteenth aspect of the present disclosure, which may be combined with any other aspect listed herein unless specified otherwise, the spray dried cacao pulp is cryo-milled.

In a nineteenth aspect of the present disclosure, which may be combined with any other aspect listed herein unless specified otherwise, a 100% cacao derived confectionery composition is provided, the composition selected from the group consisting of dark chocolate, compound coating, filling or combinations thereof comprising spray dried cacao pulp prepared with a carrier selected from the group consisting of cocoa powder, cocoa butter, or combinations thereof. In an aspect, the confectionery composition has no added sugar.

In a twentieth aspect of the present disclosure, which may be combined with any other aspect listed herein unless specified otherwise, a method of replacing a portion of the added sugar in a confectionary composition selected from the group consisting of milk chocolate, white chocolate, compound coating, filling combinations thereof, is provided, wherein the added sugar is replaced by spray dried cacao pulp prepared with a carrier selected from the group consisting of cocoa powder, cocoa butter, non-fat dried milk powder, skim milk powder, whole milk powder, powder prepared from milk substitutes, or combinations thereof.

In a twenty-first aspect of the present disclosure, which may be combined with the twentieth aspect of the present disclosure in combination with any other aspect unless specified otherwise, at least 50% of the added sugar is replaced by the spray dried cacao pulp. In an aspect, 100% of the added sugar is replaced by the spray dried cacao pulp.

In a twenty-second aspect of the present disclosure, any of the structure and functionality disclosed in connection with FIGS. 1-8 may be combined with any of the other structure and functionality disclosed in connection with FIGS. 1-8.

In a twenty-third aspect of the present disclosure, which may be combined with any other aspect listed herein unless specified otherwise, a confectionery composition is provided comprising spray dried cacao pulp prepared with a carrier selected from the group consisting of cocoa powder, cocoa butter, milk powder, and combinations thereof; wherein the confectionery composition is prepared by spray drying the ingredients and centrifuging the resulting spray dried material.

In light of the present disclosure and the above aspects, it is therefore an advantage of the present disclosure to provide a novel cacao pulp-based food and confectionery ingredient.

The advantages discussed herein may be found in one, or some, and perhaps not all of the aspects disclosed herein. Additional features and advantages are described herein, and will be apparent from, the following Detailed Description and the Figures.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an illustration of the composition of the cacao seed pod from the Theobroma cacao plant.

FIG. 2 is a schematic representation of physical changes of droplets during spray drying process (dehydration I, II and III represent the arbitrary stages of dehydration). T_(g) are glass transition temperatures, and T_(surface) is the temperature of drying particle.

FIG. 3 is a representation of the spray drying process for cacao pulp with a cocoa powder or non-fat dried milk carrier.

FIGS. 4a and 4b are ESM pictures of cacao pulp (70%)+cacao powder (30%) and cacao pulp (70%)+non-fat dried milk (NFDM) (30%), respectively.

FIGS. 5a and 5b are tables providing exemplary sugar, protein, acid, water activity, and metal levels for the spray dried cacao pulp of the present invention. FIG. 5a provides exemplary results for cacao pulp spray dried with cocoa powder and FIG. 5b provides exemplary results for cacao spray dried with milk powder.

FIG. 6 is a table showing the image, color, texture, mouthfeel and flavor for gummy candies made with the spray dried cocoa pulp of the present invention.

FIG. 7 is a representation of the particle size distribution of the sprayed cocoa butter emulsion.

FIG. 8 is an image of crystallized sugar in a cocoa butter matrix.

DETAILED DESCRIPTION

The present disclosure relates to spray dried cacao pulp. More particularly, the disclosure relates to spray dried cacao pulp as an ingredient in food and confectionery products.

Cocoa beans derived from the fruit pods of Theobroma cacao are the principal raw material for chocolate production. The cocoa beans are surrounded by a mucilaginous pulp inside the pods. After the pods are harvested, the cocoa beans (usually including at least a portion of the surrounding pulp) are recovered from the pods, while a substantial portion of the pulp may become a waste product. Accordingly, the pulp used in the method and products of the invention may preferably comprise the pulp derived from the fruit pods of Theobroma cacao. In an aspect, the pulp of the present invention may consist essentially of pulp derived from the fruit pods of Theobroma cacao.

In the present invention, the pulp is preferably derived from any species of the genera Theobroma or Herrania or inter- and intra-species crosses thereof within those genera, and more preferably from the species Theobroma cacao and Theobroma grandiflorum. The species Theobroma cacao as used herein comprises all genotypes, particularly all commercially useful genotypes, including but not limited to Criollo, Forastero, Trinitario, Arriba, Amelonado, Contamana, Curaray, Guiana, Iquitos, Maranon, Nacional, Nanay and Purus, and crosses and hybrids thereof.

The terms “cocoa” and “cacao” as used herein are considered as synonyms.

Cacao pulp comprises sugars, acids, and pectin. The primary sugars in cacao pulp are sucrose, glucose and fructose. Cacao pulp further comprises additional nutrients, including vitamins and minerals, acids and antioxidants.

In an alternative aspect, the methods and products disclosed herein are also applicable to producing food or confectionery products from other pulps, preferably pulps that would otherwise be considered waste. For example, cashew apples and coffee cherries contain pulpy fruit material in addition to the commercially desirable cashews and coffee beans. These pulps may also be spray dried to produce the novel food or confectionery ingredient. The novel food or confectionery ingredient may then be used to produce food products, confectionery products, fat-based confectionery products and the like.

In an alternative aspect, the methods and products disclosed herein may comprise fruit pulps from other fruits or berries or vegetables. For example, the fruit or vegetable material may be selected from the group consisting of strawberry, raspberry, blackberry, blueberry, guava, persimmon, pineapple, apple, mango, banana, beet, carrot, chayote, kale, pears, grapes, peas, boysenberries, lingonberries, peppers, melons, potatoes, parsnips, yams, sweet potatoes, potatoes, tomatoes, papaya, citrus fruits, pumpkins, squashes, nectarines, peaches, plums and other stone fruits and combinations thereof.

In an alternative aspect, the methods and products disclosed herein may be applied to the spray drying of pressed or cold-pressed juice from fresh cacao beans, pressed or cold-pressed juice of cacao husk, or pressed or cold-pressed juice of cacao placenta, all of which can be further concentrated by heating, evaporation, membrane filtration, or other concentration methods. Additional materials that may be spray dried include cold pressed or pressed cacao pulp (with juice and solid components processed either together or separately), fermented cacao pulp, and cacao pulp vinegar. These materials may also be homogenized, filtered, pressed or further concentrated by heating, evaporation, membrane filtration or other concentration techniques. Fermented cacao pulp may also be used to make molasses, which then can be spray dried and used as a novel ingredient according to the present method. Sweatings, the pulp or gel draining from cacao beans during fermentation can also be used in the present method and products. The sweatings may also be homogenized, filtered, pressed, concentrated, and/or turned into molasses prior to spray drying.

As used herein, the term ‘confectionery product’ or ‘fat-based confectionery product’ is to be understood as meaning a chocolate product conforming to the applicable country-based standard of identity, including but not limited to U.S. Standards Of Identity (SOI), European Standards of Identity, CODEX Alimentarius, and the like, as well as non-conforming chocolates and chocolate-like products, (e.g. comprising cocoa butter replacers, cocoa butter equivalents or substitutes), compound chocolate, a coating chocolate, a chocolate-like coating product, a coating chocolate for ice-creams, a chocolate-like coating for ice-cream, a praline, a chocolate filling, a fudge, a chocolate cream, an extruded chocolate product, an agglomerated spray dried powder for instant drinks or supplements or the like. The fat-based confectionery product may be a white chocolate; the white chocolate comprising sugar, milk powder and cocoa butter without dark cocoa solids. The product may be in the form of an aerated product, a bar, or a filling, among others. The chocolate products or compositions can be used as coatings, fillers, enrobing compositions or other ingredients in a finished or final food or confectionery product. The confectionery product of the invention may further contain inclusions such as nuts, cereals, and the like.

In an alternative aspect, the confectionery product also includes non-fat based confectionery products such as conventional sugar confectionery. These include hard candies, chewy candies, coated chewy center candies, granulated candies, candies with aerated or dense compressed centers, tableted candies, nougats, dragees, confectionery pastes, gums, chewing gums and the like.

Preparation of Spray Dried Cacao Pulp

The novel food or confectionery product is produced by spray drying fruit pulp, preferably cacao pulp. The cacao pulp is taken in its natural state and spray dried.

Spray drying is a unit operation by which a liquid product is atomized or sprayed in hot air to instantaneously obtain powder. The physicochemical properties of the final product mainly depend on inlet temperature, air flow rate, liquid feed rate, droplet size distribution, spray nozzle pressure, type of carriers and their concentration.

The ingredients that are spray dried can be divided into two main groups, non-sticky and sticky. Non-sticky materials can be easily spray dried using a simple dryer design and the final powders remains free flowing. However, sticky materials such as sugar or acid rich materials pose a technical challenge in that they stick on the interior wall of the dryer or they may get transformed into unwanted agglomerates in the dryer chamber and conveying systems. These issues lead to operating problems and low product yield.

Low product yield from poor powder recovery may be caused by the presence of low molecular weight sugars (glucose, fructose and sucrose) and organic acids (citric, malic, and tartaric) such as those found in cacao pulp.

Without being bound by theory, the high hygroscopicity (the measurement of a material's ability to absorb or release water as a function of humidity, i.e. water activity), thermoplasticity (measure by which a material can become soft when heated and hard when cooled without changing properties) and the low glass transition (Tg) of these low molecular weight substances contribute to the stickiness problem. Glass transition is the main characteristic transformation temperature of the amorphous phase.

The glass transition event occurs when a hard, solid, amorphous sugar undergoes a transformation to a soft, rubbery liquid phase. As shown in FIG. 2, the first step of spray drying is atomization of feed. Normally a concentrate solution or emulsion is atomized or sprayed into fine droplets of the range of 20-50 microns diameter. As water evaporates, the solutes in the droplets become concentrated. The physical state of the product changes as it passes through the drier from solution to syrup to solid form. The molecular mobility of these substances is high because of their low glass transition temperatures leading to issues at temperatures normally used in spray drying.

In surface energy terms, a solid glass will have low surface energy and will not stick to any other low energy solid surface. Due to the transition from glassy to rubbery state, the surface energy of the material increases and the molecules start interacting with the solid surface. In a food or confectionery product ingredient drying operation, the product is a liquid/rubbery state and due to the removal of water (plasticizer) the ingredient is converted to the glassy state. If the ingredient does not go through the transition due to a higher drying temperature than the glass transition temperature, the product will remain in a high energy sticky state.

Cacao pulp is one such sticky material. As shown in Table 1, the low molecular weight substances such as the sugars in cacao pulp are particularly sticky. Despite high hygroscopicity, thermoplasticity and low glass transition (Tg) of these low molecular weight substances, the spray drying process of the present invention yields a spray dried cacao pulp suitable for use as a food or confectionery ingredient.

TABLE 1 APROX. MELT- SOLUBILITY HYGRO- ING IN WATER SOCOPICITY POINT 60° C. Tg STICKINESS SUGAR (RELATIVE) (° C.) (% W/W) (° C.) (RELATIVE) Lactose h 223 35 101 s Maltose hh 165 52 87 ss Sucrose hhh 186 71 62 sss Glucose hhhh 146 72 31 ssss Fructose hhhhhh 105 89 5 sssss

The cacao pulp stickiness may be reduced in several ways. For example, the stickiness of the cacao pulp may be reduced through the use of low temperature and/or low humidity processes. The stickiness may also be addressed through the use of drying aids.

In an aspect, the spray dryer used for the spray drying method of the present invention is surface coated with polytetrafluroethylene (PTFE), commercially known as Teflon®. In an aspect, the spray dryer surface is coated with polychlorotrifluoroethylene, perfluoroalkoxy, tetrafluorethylene-perfluoropropylene or similar materials.

In an aspect, the cohesive stickiness is reduced by introducing protein or fat to form a glassy surface film. In a preferred aspect, the protein or fat is sourced from cocoa butter, cocoa powder, milks, milk replacement products, or combinations thereof. In aspect, the protein is sourced from plant proteins, such as chickpea protein, pea protein, or other plant proteins.

In another aspect, particle size of the cacao pulp is reduced by lowering the feed rate, increasing the spray nozzle pressure, decreasing the air flow rate, and/or increasing drying time. In an alternative aspect, post processing methods of reducing the moisture content were used prior to incorporating the spray dried cacao pulp as an ingredient in a food or confectionery product.

In an aspect, the liquid feed flow rate for the spray drying method is increased when a carrier is used. In an alternative, the flow rate is decreased.

Sugar will rarely crystallize during a spray-drying process. In this process, sugar is dissolved in aqueous solution and sprayed as droplets. While exposed to hot air, the water leaves the solution quickly, and although the solution becomes supersaturated, the crystallization kinetics are too slow for the sugar molecules to form a crystal during drying. As the mobility of the sugar molecules decrease with the lack of water, an amorphous phase is formed. When the sugar is collected at the bottom of the dryer, its temperature is lower than its glass transition temperature (Tg), which keeps it amorphous. Crystallization is further inhibited due to the impurities in the system (surfactants, stabilizers, film formers, etc.). In pulp, the presence of glucose and fructose will significantly inhibit the crystallization of sucrose. Amorphous sugar can crystallize later, when exposed to higher temperature (e.g. when processed in chocolate) or humidity. This is uncontrollable crystallization that generates large agglomerates, generating undesirable texture.

In order to enable crystallization one can slow down the drying process (difficult in spray dryers), or ensure that the particles stays above the Tg for sufficient time (for example, several minutes) to allow the particles to crystallize. Here, the risk is of residual moisture being released from the particles, which may create stickiness. Crystallization from amorphous material should be done in a dry environment while keeping particles flowing apart and separately.

In an aspect, the particles are crystallized separately.

In an aspect, the spray drying methods comprise using an inlet temperature from about 100° C. to about 205° C., and the outlet temperature from about 40° C. to about 105° C. In one aspect, the spray drying inlet temperature will be from about 100° C. to about 150° C. In another aspect, the inlet temperature will be from about 120° C. to about 200° C., or from about 120° C. to 180° C. or from about or from about 150° C. to 180° C. or from about 170° C.-190° C. or from 120° C.-140° C., or from 125° C. to 135° C. In another aspect, the outlet temperature will be from about 90° C. to about 105° C. or from 50° C. to 100° C., or from 50° C. to about 80° C., or 80° C. to 100° C., or from 55° C. to 75° C., or from 70° C. to 80° C., or from 80° C. to 90° C.

In an aspect, the air pressure used in the spray drying is 10 to 50 PSI. In an aspect, the air pressure is 20 to 40 PSI. In an aspect, the air pressure used in the spray drying method is constant.

In an aspect, the air flow rate for the spray drying method is increased when a carrier is used. In an alternative, the air flow rate is decreased.

In an aspect, a nozzle with a wide spray drying angle was used for the spray drying process. In an alternative aspect, nozzles with a narrow spray drying angle were used.

In an aspect, after spray drying, the cacao pulp does not need to be milled or otherwise processed prior to use as an ingredient in a food or confectionery product.

In an aspect, after spray drying the cacao pulp may be agglomerated to form an agglomerated product. In an aspect, the spray dried cacao pulp may be agglomerated into fat-dissolving liquid applications.

The present spray drying method allows untreated cacao pulp to be used and yields a more natural and wholesome product. The present spray drying method also allows for minimally treated (e.g., homogenized, pasteurized, commercially sterilized and/or frozen for transport) cacao pulp to be used.

In an aspect, the cacao pulp does not require any pretreatment prior to spray drying.

In an aspect, the cacao pulp does not require pH modulation. In an alternative aspect, the pH of the spray dried cacao pulp may be modulated prior to use as an ingredient.

In an aspect, the cacao pulp is preferably not processed or filtered. In an aspect, the cacao pulp is a juice. In an aspect, the cacao pulp is a concentrate.

In an aspect, the cacao pulp is fractionated. In a preferred aspect, the cacao pulp is not fractionated.

In an alternative aspect, the cacao pulp is frozen prior to spray drying. The cacao pulp may also be pureed or blended. If needed, the pulp may be pasteurized or commercially sterilized.

The spray dried cacao pulp of the present invention may be spray dried using ingredients traditionally found in confectionery products as a carrier. For example, if the spray dried cacao pulp is to be used in a fat-based confectionery product, the cacao pulp may preferably be spray dried on a cocoa powder carrier. The cocoa powder may be fermented and roasted prior to use as a carrier. In an aspect, the cocoa powder carrier may be prepared from unfermented clean dried cocoa beans. In an alternative aspect, the cocoa powder carrier may be prepared from raw, malted, or preferably germinated cocoa beans. In an aspect, the carrier may be cocoa butter or a component of cocoa butter. The carrier may be prepared from another component of the cacao pod as well, such as fiber from the cacao pod husk, bean, placenta, bean shell or testa.

The carrier may also preferably be molten cocoa butter. In that case, an emulsion of the pulp and molten cocoa butter is formed using high shear mixer. As show in FIG. 7, the emulsion is sprayed as very small droplets. The drying air removes the moisture from the droplets, and the solids stays inside the fat matrix. As droplets are less than 30 microns, the solids will be captured in the fat matrix as very small particles. The suspension of sugars in fat will deposit at the bottom of the dryer. It is kept warm to allow it to crystallize, while the particles stay separate as shown in FIG. 8. The end result is fine crystallized sugar particles (less than 30 microns) in cocoa butter. This can be used directly in the chocolate process without refining, and with minimum conching.

For example, in a milk chocolate product, the cacao pulp may be spray dried on a dairy derived or milk powder carrier such as non-fat dried milk powder. The milk powder carrier may be skim milk, 1% milk, 2% milk, whole milk or combinations thereof. The milk may be sourced from any milk producing animal. The milk powder carrier may be a milk powder replacement carrier, e.g., made with a milk replacement product such as soy milk, nut milks including cashew milk and almond milk, oat milk or combinations thereof. The cacao pulp may be spray dried with multiple carriers, such as both cocoa powder and milk powder, or cocoa powder and cocoa butter, or milk powder and cocoa butter or combinations thereof.

The carrier may also be whey protein, sodium caseinate or oat protein. In an aspect, the carrier may be a sugar or sugars. In an aspect, the carrier may be cocoa butter and a sugar. In an aspect the carrier may be cocoa powder and a sugar.

The carrier may be a soft fat, such as fractions of palm, palm kernel, coconut and shea, and blends thereof.

In an aspect, the carrier may be combined with emulsifiers such as polyglycerol polyricinoleate, or any other commercially acceptable emulsifier. In a preferred aspect, the emulsifier may include lecithin derived from vegetable sources such as soybean, safflower, corn, etc., fractionated lecithins enriched in either phosphatidyl choline or phosphatidyl ethanolamine, or both, mono- and digylcerides, diacetyl tartaric acid esters of mono- and diglycerides (also referred to as DATEM), monosodium phosphate derivatives of mono- and diglycerides of edible fats or oils, sorbitan, monostearate, hydroxylated lecithin, lactylated fatty acid esters of glycerol and propylene glycol, polyglycerol esters of fatty acids, propylene glycol mono- and di-esters of fats and fatty acids, or emulsifiers that can become approved for the US FDA-defined soft candy category. In addition, other emulsifiers that can be used include ammonium salts of phosphatidic acid (e.g., YN), sucrose esters, oat extract, etc., any emulsifier found to be suitable in chocolate or similar fat/solid system or any blend.

In an aspect, the carrier is an ingredient commercially acceptable for inclusion in a fat-based confectionery product. For example, in an aspect, the carrier is a nut-meat powder sourced from any commercially acceptable nut. In another aspect, the carrier is isolated solids or flours derived from nuts.

In an aspect, the ratio of cacao pulp to carrier is present in a weight ratio of about 40:60. In an aspect, the weight ratio of cacao pulp to carrier is about 70:30. In an aspect, the ratio of cacao pulp to carrier is about 80:20. In an aspect, the ratio of cacao pulp to carrier is about 50:50 by weight.

In an aspect, the solid content of the cacao pulp and carrier is about 10% to 50% solids. In another aspect, the solid content of the pulp and carrier is about 10% to 30% solids, or about 15% to 30% solids, or preferably about 15% to 25% solids.

In an aspect, the spray dried cacao pulp is used in a non-fat based confectionery product. In addition to the carriers described above, the carrier may be acacia gum (e.g., gum Arabic), starches, modified starches, maltodextrins, corn syrup solids, alginates, agar, gelatin, methyl cellulose, cyclodextrin, or other carriers or combinations thereof. In one aspect, the acacia gum is gum arabic (from Acacia Senegal). In another aspect, the carrier may be a plant protein, such as a chickpea, pea or other plant protein.

In an alternative aspect, the carriers described for use with cacao pulp for non-fat based confectionery products may be used for cacao pulp prepared for fat-based confectionery products.

In an aspect, the presently disclosed spray drying methods yield a spray dried cacao pulp product with high levels of micronutrients, including antioxidants such as polyphenols.

In an aspect, the presently disclosed spray drying methods yield a spray dried cacao pulp ingredient with less than about 10% moisture. In an aspect, the spray dried cacao pulp has less than about 8% moisture. In yet another aspect, the moisture level in the spray dried cacao pulp is less than about 5%. In an aspect, the moisture level is less than 1.5%.

In an aspect, the spray dried cacao pulp is crystallized prior to use as an ingredient in food or confectionery products. In an aspect, the spray dried cacao pulp is pre-crystallized by heating a drying oven at 50-100° C., more preferably 60-80° C., more preferably 70-75° C.

In an alternative aspect, the spray dried cacao pulp is crystallized through mixing in a heated mixer.

The spray dried cacao pulp may be milled after crystallization occurs. Preparation of Fat-Based Confectionery Products

In an aspect, the spray dried cacao pulp is used as an ingredient in the production of fat-based confectionery products, such as chocolate products.

In an aspect, fat-based confectionery products are prepared from cocoa beans. The roasted cocoa beans may be further roasted and winnowed to generate a nib that is converted to cocoa liquor or cocoa butter. The nib or cocoa liquor may be converted to cocoa powder. The liquor, cocoa butter, and nib may be mixed with sugar or other natural or synthetic sweetening substances, either alone or optionally with other ingredients suitable for used in fat-based confectionery. The spray dried cocoa pulp may be added to the mixer alone, or in combination with other ingredients.

The cocoa butter, cocoa liquor and spray dried cacao pulp and optionally other ingredients may be heated while being mixed. The mixture may be heated in a jacketed mixer with a water bath at about 80-100° C., preferably about 90-100° C. The heated mixture may be mixed for about 0.5 to 2 hours, preferably about 1-2 hours. The material may be mixed at increasing speed. Alternatively, the mixture may be mixed at high speed.

In some aspects, the resulting mixture may be in the form of a paste. In an aspect, the sweetening substance added is spray dried cacao pulp.

The paste may be refined, optionally by means of a roller system or other chocolate milling approaches, in order to generate smaller particle sizes within the paste. According to further aspects, milk solids may be added, and the mixture then further processed to a milk crumb. This mixture may be mixed in a conche, optionally with cocoa butter and emulsifier. The paste and crumb may also be mixed with cocoa butter and emulsifier in a conche.

The end product of this process of preparing, and optionally refining and further processing the paste is an edible cocoa containing product, including, but not limited to, a chocolate, a compound chocolate, or a chocolate-like substance.

In an aspect, the spray dried cacao pulp is used to replace sugar in the fat-based confectionery product. In an aspect, the fat based confectionery product comprising spray dried cacao pulp does not include any additional sugar. In an aspect, the product does not include any refined sugar. The spray dried cacao pulp may also be used to replace all or some sugar in foods or in non fat-based confectionery.

In an aspect, the spray dried cacao pulp may be used to replace texture agents such as gelatin, pectin, starches, or the like.

In an aspect, the spray dried cacao pulp may be used as a bulking agent.

In an aspect, the fat-based confectionery products comprising cacao pulp do not require additional processing or tempering as compared to fat-based confectionery products not comprising cacao pulp.

In an aspect, the fat based confectionery product comprising the spray dried cacao pulp of the present invention is produced at a lower temperature as compared to a similar fat based confectionery product not comprising cacao pulp. In an aspect, conching occurs at less than 30° C. In an aspect, conching occurs at 50° C. to 80° C. In an aspect, conching occurs at less than 50° C. to 60° C. In an aspect, milling of the ingredients in the fat-based confectionery product occurs at less than 50° C. to 80° C. In an aspect, milling occurs at less than 30° C. In an aspect, milling occurs at less than 50° C. to 60° C. In an aspect, conching and milling occur at the same temperatures. In an aspect, conching and milling occur at different temperatures. In another aspect, cryo-milling techniques are used to maintain low temperatures.

In an aspect, the spray dried cacao pulp is milled separately from the other ingredients of the fat-based confectionery product. In another aspect, raw materials comprising spray dried cacao pulp are milled separately from other ingredients.

In an aspect, the spray dried cacao pulp, or the raw materials comprising the spray dried cacao pulp are conched separately from other ingredients.

In an aspect, the spray dried cacao pulp or the raw materials comprising the spray dried cacao pulp are combined with other chocolate ingredients, or chocolates, or compounds, or fillings or combinations thereof after conching, milling, or at a later step in the manufacturing process.

In an alternative aspect, fat based confectionery products may be produced through a non-traditional chocolate making method using a spray dryer and centrifuge (“spray dryer method”). No additional milling, conching or other steps are needed. In an alternative aspect, the cocoa liquor may be milled.

In this spray dryer method, all the spray dryer parameters disclosed above may expressly be combined with this method.

In this spray dryer method, all ingredients, carriers, and other preparations disclosed above may expressly be combined with this method. For example, in an aspect, the cocoa liquor, cocoa butter and spray dried cacao pulp, optionally with other ingredients may be combined in a spray dryer. Spray drying the material results in a water in fat emulsion with a particle size of 30 microns or less. The emulsion is kept warm, allowing the sugars present to crystallize.

All the ingredients in a standard chocolate recipe may be combined in a spray dryer and spray dried in accordance with the parameters described herein. In a preferred aspect, cocoa liquor, cocoa butter, lecithin and cocoa pulp are spray dried.

In an alternative aspect of the spray dryer method, sugar may be added. The sugar may be added in the form of a sugar syrup. Alternatively, the sugar syrup may be molasses, including date molasses, grape molasses or molasses made from other fruits. In an alternative aspect, fruits other than cacao pulp may be added to the spray dryer.

The spray dried cocoa pulp and ingredients may then be centrifuged. The centrifuged material may be formed into bars, truffles, centers, lentils, tablets, or other shapes appropriate to fat-based confections. The centrifuged material may alternatively be used as an ingredient in other confectionery or food products. The centrifuged material may have a particle size of 30 microns or less.

In an aspect, the centrifuged material may be subjected to further processing. In an aspect, the additional processing, milling and/or refining steps reduce the particle size to less 30 microns, such as 20 microns or 10 microns.

In an aspect, the centrifuged material may be used as an ingredient in a standard chocolate making process.

In an aspect, the centrifuged material may be used to produce fine flavor chocolate, premium chocolate, small batch chocolates, 100% cacao chocolates, or single origin chocolates.

The presently disclosed subject matter may be additionally understood by reference to the following Examples, which are provided as exemplary of the invention, and not by way of limitation.

EXAMPLES

The presently disclosed subject matter will be better understood by reference to the following Examples, which are provided as exemplary of the invention, and not by way of limitation.

Example 1—Spray Dried Cacao Pulp with Milk Proteins

In accordance with an aspect of the present invention, as a control, as shown in Batch 1 and Batch 2 in Table 2, cacao pulp was spray dried without any carrier. As also shown in the Table, yields of 11% were obtained from Batch 1 and Batch 2. 89% of the material stuck to the dryer.

As reflected in Table 2, using the same spray drying parameters as for cacao pulp alone, cacao pulp was combined with a carrier and then spray dried. The carriers tested were whey protein isolate (WPI) and sodium caseinate, alone or in combination with maltodextrin. In contrast to the controls 1 and 2, as shown in Table 2 in Batches A-D, approximately 50-60% of the spray dried pulp was recovered and usable as a spray dried pulp ingredient.

In an alternative formulation, polyglycerol polyricinoleate (PGPR) was combined with cacao pulp and whey protein isolate, which was then spray dried. In that case, 74% of the spray dried material was recovered and usable as spray dried cacao pulp ingredient.

TABLE 2 BATCH 1 2 A B C D Cocoa pulp 411 361 500 500 0 0 (blended) (g) Cocoa pulp 0 0 500 500 (unblended) (g) Brix of juice 17.6 17.6 16.7 16.7 16.7 16.7 Juice Total Solid 72.36 63.5 83.5 83.5 83.5 83.5 Content (g) Whey Protein 12.52 12.52 12.52 12.52 Isolate (g) Maltodextrin (g) 4.18 4.18 4.18 4.18 Water (g) 25 25 25 25 Final Brix % 18.1 18.6 17.8 19.3 Total Solids (g) 72.36 72.36 100.2 100.2 100.2 100.2 VARIABLE Brix % 12.70 12.60 18.1 19.2 17.8 19.3 Yield (%) 11.2 11.6 63.4 60.54 59.61 55.7

The spray-dried cacao pulp was then used to make a chocolate product with no added sugar using standard chocolate-making techniques.

Example 2—Spray Dried Cacao Pulp with Cocoa Powder or Non-Fat Dried Milk

As shown in Table 3, cacao pulp was combined with cocoa powder. The cacao pulp was otherwise untreated. The cocoa powder and cacao pulp combination was spray dried following the parameters as shown in Table 3. The process yielded approximately 43% usable spray dried cacao pulp. After coating the spray dryer with PTFE, the yields increased to about 70%.

TABLE 3 Cacao Pulp Cacao (% of Cacao Cacao Pulp Cacao Added Total PTFE Pulp Pulp (solids) Pulp Cacao Solids Inlet Outlet Yield Yield Coating? (g) (Brix %)) (g) solids) Powder (g) Brix % Temp. Temp. (g) (%) No  500 g 19.5% 98 30 29.4 127.4 20.4 110° C.- 50° C.- 55 43 150° C. 100° C Yes 3553 19.7 699.9 30 209 908.9 20.7 110° C.- 50° C.- 638 70.18 150° C. 100° C

Similar results were seen when cacao pulp was combined with non-fat dried milk as a carrier. Yields of 85% were obtained of the spray dried cacao pulp. As shown in FIGS. 5a and 5b the final spray dried cacao pulp product prepared with cocoa powder as the carrier (5a) and the final spray dried cacao pulp product prepared with non-fat dried milk (NFDM) as the carrier (5b) both had high levels of sugars, rendering them useful to replace added sugar in confectionery products. As shown in FIGS. 3a and 3b , the type of carrier did not influence the morphology of the spray dried cacao pulp. Particles with both carriers showed spherical shapes of varying sizes.

TABLE 4 Cacao Cacao Cacao Cacao Pulp Pulp Added Total Pulp Pulp (solids) (% of NFDM Solids Inlet Outlet Yield Yield PTFE (g) (Brix %)) (g) NFDM) (g) (g) Brix % Temp. Temp. (g) (%) Yes 2987 20 597 30 179 775 23.8 110° C.- 50° C.- 812 85 150° C. 100° C

Example 3—Spray Dried Cacao Pulp with Cocoa Butter

Cacao pulp was combined with molten cocoa butter and lecithin in a high shear mixture to achieve a water-in-oil emulsion. The emulsion was kept at temperature above 70° C., and then spray dried at 65° C.-140° C. (air inlet temperature). After drying and water removal, the process yielded a suspension of fine solids (sugars, pectin and other pulp ingredients) in molten cocoa butter. The suspension was kept warm for 15 minutes to allow the sugars to crystallize and for the excess of moisture to evaporate. The continuous matrix of fat kept the particles apart and eliminated aggregation, which resulted in fine crystals. The suspension then was centrifuged to remove access of cocoa butter. After the majority of the cocoa butter was removed, the concentrated suspension was used in chocolate formulation.

Example 4—Preparation of a Chewing Gum

In accordance with an aspect of the present invention, the inventors prepared a chewing gum comprising spray dried cacao pulp. The cacao pulp was spray dried as described in Example 2, above. Two formulations of the spray dried cacao pulp ingredient were prepared, one with 85% cacao pulp and 15% maltodextrin as the carrier, and one with 70% cacao pulp and 30% cocoa powder as the carrier. The carrier and cacao pulp were spray dried, yielding the novel ingredient of the present invention. The ingredient was then added to a chewing gum.

The chewing gum was 70% spray dried cacao pulp and 30% gum base.

The chewing gum did not comprise any added sugar. The only sweetener was the spray dried cacao pulp.

The chewing gum was sweet with a pleasantly fruity flavor.

Example 5—Preparation of a Gelatin Based Fruit Candy

In accordance with an aspect of the present invention, the inventors prepared a gelatin candy with the spray dried cacao pulp as a replacement for varying percentages of the sugars traditionally used in gummy candies.

Three trials were conducted. A control traditionally made gummy candy was prepared. In the first trial, 10% of the cane sugar traditionally found in gummy candies was replaced with spray dried cacao pulp with maltodextrin and sodium citrate to equilibrate the pH as the spray dried pulp was approximately 3% acidity. The second trial 5% of the cane sugar with spray dried cacao pulp with maltodextrin and sodium citrate to equilibrate the pH as the pH of the product dropped during the addition of the spray dried cacao pulp from 5.8 to 4.5.

Addition of sodium citrate stabilized the pH at 5.2.

As shown in FIG. 6, replacing part of the sugar with spray dried cacao pulp produced products with elastic textures desirable in a gummy candy.

Trial 1 (10%) showed gelatinization before the addition of the gelatin solution. Without wishing to be bound by theory, the pectin in the spray dried cacao pulp may be responsible for the gelatinization. Accordingly, spray dried cacao pulp of the present invention may be used to replace gelatin, starch or pectin from other sources as well as to serve a sugar replacement function.

Example 6—Ice Cream

In accordance with an aspect of the present invention, spray dried cacao pulp was used as a sweetener in ice cream. The ice cream may be prepared using standard recipes, replacing the sugar with the same volume of spray dried cacao pulp. The ice cream composition is as follows, in accordance with the standard of identity.

Ice Cream Composition

Milkfat: >10%-16%

Milk solids-not-fat (snf): 9%-12%

Sucrose: 10%-14% (replaced with cacao pulp as the sweetener)

Corn syrup solids: 4%-5%

Stabilizers: 0%-0.4%

Emulsifiers: 0%-0.25%

Water: 55%-64%

The ingredients were sprayed in a spray dryer and then centrifuged. Sticks or handles were inserted to allow the ice cream to be consumed.

Example 7—Spray Dryer Method Chocolate Comprising Spray Dried Cacao Pulp

In accordance with an aspect of the present invention, a chocolate comprising spray dried cacao pulp was prepared in a spray dryer.

The following material was added into the spray dryer: 3000 grams cocoa butter, 400 grams cocoa liquor, and 2000 grams of cocoa pulp were added into the spray dryer. Optionally, lecithin was added. The material was mixed to create a fine water in oil emulsion.

Prior to spraying, the material was kept at 50 C.

The material was spray dried at an inlet temperature of 130-160 C. The material was spray dried for less than ten seconds, preferably for less than five seconds. The resulting suspension of fine particles in fat was kept at temperature above the glass transition temperature of the sugars for about ten minutes to allow crystallization to occur.

The resulting emulsion was centrifuged to remove the excess fat. The resulting material had a moisture level of less than 1.0 and a fine particle size resulting in a smooth chocolate.

The chocolate had the following composition:

TABLE 5 Moisture content 1.0 (Karl Fischer) Particle size 30 micron Sugar content (all sugars ~28% naturally occurring from spray dried cacao pulp with no added sugar) Fat content ~50% Cocoa Liquor ~34% Lecithin Less than 1%

The material produced herein may be further processed, through milling or other processing to achieve a smaller particle size distribution.

The produced material is suitable for consumption as a final product or alternatively may be used as an ingredient to produce confectionery products.

Example 8—Preparation of Fruit Confections

In accordance with an aspect of the present invention, a fruit confection was prepared.

1000 grams of cocoa pulp material was added to a blender along with 1500 grams of cocoa butter. Optionally, 2500 to 3000 grams cocoa liquor is added. The material was added into the spray dryer and spray dried to create a water in fat emulsion. The resulting suspension of fine particles in fat was kept at temperature above the glass transition temperature of the fruit sugars to allow crystallization to occur.

The resulting material was then centrifuged to remove excess fat, yielding a fruit confection with a particle size of less than 30 micron.

The resulting material may then be further processed to reduce particle size to 20 micron, or 10 micron.

The produced material is suitable for consumption as a final product or alternatively may be used as an ingredient to produce confectionery products.

Example 9—Chocolate Sweetened Only with Spray Dried Cacao Pulp

In accordance with an aspect of the present invention, a chocolate comprising spray dried cacao pulp was prepared using standard chocolate making methods.

First, spray dried cacao pulp was prepared in accordance with the present invention, using cocoa powder as the carrier at a ratio of 70:30 cacao pulp:cocoa powder. The cacao pulp was sprayed on a cocoa powder carrier using an air inlet temperature of 130° C.-150° C. for less than 10 seconds. The resulting spray dried cacao pulp had a moisture level of 0.75%.

Chocolate was prepared by combining the spray dried cacao described above with cocoa butter and cocoa liquor.

TABLE 6 Ingredient Percentage of Total Composition Spray dried cacao pulp:cocoa ~60% powder (70:30 ratio) Cocoa Butter ~30% Cocoa Liquor ~10%

The three materials were mixed on low speed for 10 minutes in a jacketed mixer, with temperature maintained at 45 C. The resulting mixture was refined in a cooled roll refiner, producing refiner flakes. The material was kept below 40 C. The material was refined to an average particle size of 19 μm.

After refining, the refiner flakes were mixed in a jacketed mixer set at 45° C. on low speed, with temperature lowered to 40° C. after 45 minutes of conching. A portion of the total cocoa butter was added prior to the temperature reduction, with the rest added after additional conching, keeping the temperature below 40° C.

The finished chocolate had an average particle size of 19 μm measured by micrometer. The apparent viscosity was measured with a Brookfield RV T-A Spindle 4 rpm, yielding 100F: 26,600 cps.

The chocolate was tempered, cooled and formed into bars.

This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims. 

1. A confectionery composition comprising spray dried cacao pulp prepared with a carrier selected from the group consisting of cocoa powder, cocoa butter, milk powder, and combinations thereof.
 2. The composition of claim 1, wherein the milk powder is selected from the group consisting of non-fat dried milk powder, skim milk powder, whole milk powder, or powder prepared from milk substitutes.
 3. The composition of claim 1, wherein the composition does not comprise any added sugar.
 4. A method of manufacturing a food or confectionery ingredient comprising spray drying cacao pulp with a carrier.
 5. The method of claim 4, wherein the carrier is cocoa powder, cocoa pod fiber, cocoa butter or another product derived from a cocoa pod.
 6. The method of claim 4, wherein the cacao pulp is unprocessed prior to spray drying.
 7. The method of claim 4, wherein the spray drying occurs at an inlet temperature of 120° C. to 180° C.
 8. The method of claim 4, wherein the spray drying occurs at an outlet temperature of 60° C. to 100° C.
 9. The method of claim 4, wherein the spray drying occurs in a spray dryer coated with polytetrafluroethylene.
 10. (canceled)
 11. (canceled)
 12. A composition comprising a confectionery ingredient produced by the method of claim 4, wherein in the composition is a non-fat based confectionery product.
 13. (canceled)
 14. (canceled)
 15. (canceled)
 16. The non-fat based confectionery of claim 10, wherein the chewing gum does not comprise any added sugar.
 17. A method of producing a chocolate or a compound coating comprising adding spray dried cacao pulp to the chocolate or the compound coating wherein the spray dried cacao pulp is milled or conched separately from other ingredients prior to addition to the chocolate or the compound coating.
 18. (canceled)
 19. (canceled)
 20. The method of claim 17, wherein the chocolate or the compound coating is milled or conched at less than 50° C.
 21. The method of claim 17, wherein the chocolate or the compound coating is cryo-milled.
 22. (canceled)
 23. A 100% cacao derived confectionery composition selected from the group consisting of dark chocolate, compound coating, filling and combinations thereof comprising spray dried cacao pulp prepared with a carrier selected from the group consisting of cocoa powder, cocoa butter, and combinations thereof wherein the composition does not comprise any added sugar.
 24. (canceled)
 25. A method of replacing a portion of the added sugar in a confectionary composition selected from the group consisting of milk chocolate, white chocolate, compound coating, filling and combinations thereof, wherein the added sugar is replaced by spray dried cacao pulp prepared with a carrier selected from the group consisting of cocoa powder, cocoa butter, non-fat dried milk powder, skim milk powder, whole milk powder, powder prepared from milk substitutes, and combinations thereof.
 26. (canceled)
 27. (canceled)
 28. (canceled)
 29. (canceled) 